ENVIRONMENTAL PRODUCT DECLARATION DAPc.002.010 PRODUCT Medium porcelain stoneware tiles COMPANY IN ACCORDANCE WITH ISO STANDARDS 14.025 & 21.930 DESCRIPTION OF THE PRODUCT The product includes different formats of porcelain stoneware tiles (BIa). PCR REFERENCE PCR 002 Ceramic tile products V.1 (2010) PRODUCTION PLANT, S.A. CV16 (Ctra. CastellónAlcora) Km. 2,200 P.O.Box 157 12080 Castellón España VALIDITY From : 16.09.2013 To: 16.09.2018 The validity of the DAPc 002.010 is subject to the conditions of the DAPc regulations. The relevant version of this DAPc is included in the register kept by the CAATEEB; for more information, consult the system s website: http://es.csostenible.net/dapc 1
Environmental Product Declaration for MEDIUM PORCELAIN STONEWARE TILES 1. Description of the product and its use The porcelain stoneware tiles are classified in group BIa (dry pressed ceramic tiles with a low water absorption of 0.5% or less) as per ISO 13006 and UNEEN 14411:2007. Table 1. Product included and dimensions Finishes Product Group Dimensions (cm x cm) PORCELAIN STONEWARE TILES AND FULL BODY PORCELAIN STONEWARE TILES BIa Unrectified Rectified Polished Unpolished 14.5/19.5x120, 15x60, 15x80, 22x90, 30x30, 30x60, 40x80, 45x45, 45x90, 60x60, 60x120 and 80x80 The main recommended use for this product is for tiling walls and floors. 2. Description of the life cycle phases 2.1. Manufacture (A1, A2 and A3) Raw materials (A1 and A2) The porcelain stoneware tile product (BIa) basically consists of clay, sand and feldspar with a glaze layer mainly consisting of feldspar, carbonate, silicate and kaolin, among other materials. The raw materials used come from different origins (local, national, Turkey, Ukraine, Italy or the United Kingdom). This variation is due to the impossibility of obtaining these raw materials from a single source. The raw materials from outside of Spain are transported by freighter to the port of Castellón and from there by truck to the plant for manufacturing the spraydried powder. For marine transport, a transoceanic freighter is used, whose transportation distance varies in each case depending on the point of origin. The raw clay materials are transported in bulk, meaning packaging materials are not required. The frits are transported in bigbags on pallets. Manufacturing (A3) The industrial process at the plant in Castellón starts with the reception of the spraydried clay in metal hoppers ready to receive the clay from the transportation trucks. The clay is then transported to the corresponding storage silos on unloading and conveyor belts. The clay is then transported to the presses using conveyor belts, where if necessary it can be treated in a technological tower or a colouring system to create specific types of effects. 3
The presses are hydraulic, fully automated and electronically controlled. The clay is poured into moulds using a feeder carriage, which first removes the tiles from the previous run. These tiles are transferred to a collecting belt on which they are carried to the vertical driers, where their residual moisture is removed. The different components of the glazes, such as frits, colours and additives, are loaded together with water into mills with grinding fillers. Once they have been ground, the glaze is poured into vats with stirrers to prevent the different components from precipitating, from where they are pumped or transported to the glazing line. The glazing line is equipped with systems for transporting the tiles. The different glazes used for each model are applied as a waterbased suspension in each of the devices (disks, bell glazing units, spray guns) positioned along the line. Once the tiles have been glazed and decorated, they are collected by a loading machine that stacks them on racks in an intermediate storage area ready for firing in the kilns. The kilns are single layer type. The tiles pass through them on rollers that are resistant to high temperatures. Once the tiles have been fired, they are stacked on AGVs and taken to the sorting area. Before entering the sorting lines, the tiles can be rectified and/or polished. This section for polishing, cutting and rectifying the tiles makes it possible to process a part of the production in order to obtain tiles with an exceptional surface gloss (when polished), smaller tiles made from larger sections (when cut), and/or tiles with an extraordinary dimensional precision, also making it possible to eliminate the typical rounded edges found on tiles (when rectifying). There is also a cutting section, whose work focuses on obtaining extremely small formats from larger tiles. Once on the sorting lines, whether the tiles have passed through the rectifying and polishing section or not, the AGVs are unloaded again and the tiles placed on a belt where they undergo a visual inspection and are marked according to their qualities, then separated onto the corresponding output lines. On the line, there is a device for measuring the flatness of the tiles and a calliper to measure the squareness of the tiles. Finally, there is an automatic packaging system and robotic palletising system. The sorted tiles are packed in cardboard packaging. The number of tiles in each box will vary depending on their format and weight. The different cardboard boxes are stacked on wooden pallets, which are then covered with LDPE shrink or heat shrink film, which adapts to the size of the pallets. Once the pallet is complete, it is stored in the corresponding area. 4
2.2. Construction Transporting the product (A4) Not included in the scope of the study system. Process of installing the product and construction (A5) Not included in the scope of the study system. 2.3. Use of the product The use phase is divided into the following modules: Use (B1) Maintenance (B2) Repair (B3) Replacement (B4) Refurbishment (B5) Operational energy use (B6) Operational water use (B7) Not included in the scope of the study system. 2.4. End of life The endoflife phase includes the following modules: Deconstruction and demolition (C1) Transport (C2) Waste management for reuse, recovery and recycling (C3) Final disposal (C4) Not included in the scope of the study system. 2.5. Module D: potential environmental benefits and impacts derived from activities of reuse, recovery and recycling Module D declares the existence of environmental credits (i.e. environmental impacts that have been avoided) due to the reuse, recovery or recycling of some of the output flows from the system. The net impacts declared will be the result of calculating the impacts of the production of the raw, displaced or replaced materials or fuels, minus the environmental impacts of the reuse, recovery and recycling operations. 5
Impacts are considered to have been avoided in: The management of waste from containers and packaging produced during the manufacturing stage, The electrical power generated during the spraydrying process which is sold to the electricity grid. Module A1 includes the environmental impacts caused by burning natural gas during the spraydrying process, thermal energy used for spraydrying, and the electricity generated from cogeneration. Part of this electricity is used in the spraydrying facilities and tile manufacture, and part is sold to the electricity grid. The environmental benefits produced by the displaced energy are quantified in Module D. 3. Life cycle analysis The life cycle analysis on which this declaration is based has been carried out as per ISO standards 14040 and 14044, and the document PCR 002 Ceramic Tile Products, Version 1 2010.06.11. This LCA is cradletofactory gate, i.e. it covers the phases of the manufacture of the product, but does not include its phases of construction, use and end of life. Specific data has been used from the plant in Castellón for the year 2012 to inventory the manufacturing phase. 3.1 Functional unit The declared functional unit is 1 m 2 of MEDIUM PORCELAIN STONEWARE TILES 6
3.2. Limits of the system Figure 1: Limits of the System 7
3.3. Impact evaluation indicators Table 4. Impact evaluation indicators Parameter evaluated Unit per m² of panel Manufacture Construction A1. A3. A4. A5. Potential for global warming Kg of CO2 eq. 1.26E+01 Potential for depletion of stratospheric ozone Kg of CFC11 eq. 1.44E07 Potential for acidification Kg of SO2 eq. 3.33E02 Potential for eutrophication Kg of PO4 eq. 5.86E03 Potential for depletion of abiotic resources Kg of Sb eq. 1.02E01 Potential for formation of photochemical Kg of ethane eq. 1.18E03 Potential for depletion of abiotic resources (fossil resources) MJ 2.12E+02 A1. Supply of raw materials A2. Transport A3 Manufacture (as per figure 1) A4. Transport A5. Installation and construction processes B1. Use B2. Maintenance and transport B3. Repair B4. Replacement B5. Refurbishment B6. Operational energy use B7. Operational water use B1. Life cycle stage Use B2. B3. B4. B5. C1. Deconstruction and demolition C2. Transport C3. Waste management for reuse, recovery and recycling. C4. Final disposal End of life B6. B7. C1. C2. C3. C4. The PCR do not provide for the calculation of this impact, as it is not relevant for this type of product. 8
3.4. Life cycle inventory data Table 5. Life cycle inventory data Parameter evaluated Unit per m² of panel Manufacture Construction A1. A3. A4. A5. Consumption of primary renewable energy MJ(net calorific 1.65E+01 Consumption of primary nonrenewable energy MJ(net calorific 2.20E+02 Use of nonrenewable secondary fuels MJ(net calorific 0.00E+00 Use of renewable secondary fuels MJ(net calorific 0.00E+00 Consumption of fresh water m3 6.60E02 Production of waste kg 1.61E+00 Hazardous kg 3.99E4 Nonhazardous kg 1.61E+00 Radioactive kg 1.85E4 Material released for kg 1.24E2 Reuse kg 0.00E+00 Recycling kg 1.24E2 Energy recovery kg 0.00E+00 A1. Supply of raw materials A2. Transport A3 Manufacture (as per figure 1) A4. Transport A5. Installation and construction processes B1. Use B2. Maintenance and transport B3. Repair B4. Replacement B5. Refurbishment B6. Operational energy use B7. Operational water use B1. Life cycle phase Use B2. B3. B4. B5. C1. Deconstruction and demolition C2. Transport C3. Waste management for reuse, recovery and recycling C4. Final disposal End of life B6. B7. C1. C2. C3. C4. The PCR do not provide for the calculation of this impact, as it is not relevant for this type of product. 9
3.5. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling Appendix 1 Table 4. Impact evaluation indicators Reuse, recovery and recycling Appendix 1 Table 5. Life cycle inventory data Reuse, recovery and recycling Parameter evaluated Unit per m² of panel D. Parameter evaluated Unit per m² of panel D. Potential for global warming Kg of CO2 eq. 6.82E01 Potential for depletion of stratospheric ozone Kg of CFC11 eq 5.40E09 Potential for acidification Potential for eutrophication Potential for depletion of abiotic resources Potential for formation of photochemical ozone Potential for depletion of abiotic resources (fossil resources) Kg of SO2 eq. Kg of PO4 eq. Kg of Sb eq. Kg of ethane eq. 3.41E04 2.23E04 5.38E03 1.42E05 1.11E+01 D. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling Consumption of primary renewable energy Consumption of primary nonrenewable energy Use of nonrenewable secondary fuels Use of renewable secondary fuels Consumption of fresh water MJ (net calorific MJ (net calorific MJ (net calorific MJ (net calorific m 8.99E01 1.49E+01 0.00E+00 0.00E+00 6.5E03 Production of waste Kg 7.17E02 Hazardous Kg 2.61E05 Nonhazardous Kg 7.10E02 Radioactive Kg 7.14E04 Material released for Kg 0.00E+00 Reuse Kg 0.00E+00 Recycling Kg 0.00E+00 Energy recovery kg 0.00E+00 D. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling 3.6 Recommendations of this DAPc Construction products should be compared by applying the same functional unit and level of building, i.e. including the product s behaviour throughout its life cycle. Environmental product declarations of different systems of type III ecolabelling are not directly comparable, as the rules for calculation may be different. This declaration represents the average behaviour for the porcelain stoneware tile product manufactured by 10
3.7. Cutoff rules More than 95% of the inputs and outputs of mass and energy of the system has been included, excluding the following: Diffuse emissions of particles into the atmosphere produced during the transportation and storage of powdered raw materials. Channelled atmospheric contaminants produced during the combustion phases (spraydrying, drying and firing of tiles) not provided for by applicable legislation. The process of recycling and reusing the waste produced during the life cycle of the tiles due to the method used for allocating impacts. The production of industrial machinery and equipment due to the difficulty of including all of the elements involved in an inventory, and also because the LCA community considers that the environmental impact per product unit is low in relation to the rest of the processes that are included. Also, the databases used do not include these processes, and so their inclusion would require an additional effort beyond the scope of the study. 3.8. Other data Waste from the ceramics industry is included as nonhazardous waste in the European Waste Catalogue under EWC code 101200: Waste produced by the manufacture of ceramic products and EWC 101229 Waste unspecified in other categories (Decision 2000/532/EC). 4. Technical information and scenarios Not included in the scope of the system. 5. Additional information Technical characteristics of the product Declaration of performance Euroclass of reaction to fire: A1 FL / A1 Breaking strength > 1300 N BIa group water absorption 0.5% Modulus of rupture (N/mm 2 ) > 50 Resistance to thermal shock: resistant Crazing resistance: resistant Frost resistance: resistant Certified by the implementation of a Quality System that meets the requirements of ISO 14001:2004. Certified by the implementation of a Quality System that meets the requirements of ISO 9001:2008. CE Marking (Declaration of Performance) 11
6. PCR and inspection This declaration is based on the document PCR 002 Ceramic Tile products V.1. PCR002 Ceramic Tile Products V.1. was revised by the Advisory Board of the DAPc system. Independent verification of the declaration and data as per ISO 14025:2006 standard internal external Thirdparty inspector: Xavier Folch Berenguer, ITeC Date of verification: 13 September 2013 References Life cycle analysis of PORCELAIN STONEWARE TILES. ReMaMEDIOAMBIENTE, S.L. for 2013 (unpublished) SYSTEM ADMINISTRATOR Collegi d Aparelladors, Arquitectes Tècnics i Enginyers d Edificació de Barcelona (CAATEEB) Bon Pastor 5, 08021 Barcelona www.apabcn.cat 12